101601-5801 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015801

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5801 1016015801

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Service parts 101601-5801 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-5310

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0240

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder 23600-1593A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-0490

15. NOZZLE SET

Include in #1:

101601-5801 as INJECTION-PUMP ASSEMBLY

Include in #2:

104207-3000 as _

Cross reference number

ZEXEL 101601-5801 1016015801

Zexel num

Bosch num

Firm num

Name

101601-5801

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 42.4 46.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 43.4 45.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 43.5 41.5 45.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 44.1 42.1 46.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 36.2 34.2 38.2

Fixing the lever *

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL
----------
T1=93 RAL=(R1+0.2)+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

North America Only:When a problem arises concerning the sale, operation or service of your engine, it will normally be handled by the dealer in your area. The service facility nearest you can be located twenty-four hours a day by calling the appropriate phone numbers listed below.In U.S. and Canada 1 (800) 447-4986.Your satisfaction is a primary concern to Caterpillar and its dealers. If you have a problem that has not been handled to your satisfaction, we suggest the steps that follow: Step OneDiscuss your problem with a member of management from the dealership. Step TwoWhen it appears that your problem cannot be readily resolved at the dealer level without additional assistance, use the above telephone numbers and ask to talk to a Field Service Coordinator. Regular Monday through Friday business hours are from 8:00 a.m. to 4:30 p.m. Central Standard Time (CST). Step ThreeIf you are still not satisfied, present the engine matter in writing to:Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg. A
P.O. Box 600
Mossville, Illinois 61552-0600
When contacting the Manager, Customer Service, please keep in mind that ultimately your problem will likely be resolved at the dealership, using their facilities, equipment, and personnel. Therefore, it is suggested that you follow the above steps in sequence when experiencing a problem. Outside North America:If a problem arises outside North America, and cannot be resolved at the dealer level, contact the appropriate Caterpillar subsidiary office. Mid and South America (except Brazil):Caterpillar Americas Co.
100 NE Adams Street
Peoria, Illinois 61629 U.S.A.
Phone: 309-675-5876
Brazil:Caterpillar Brazil S.A.
04795-Av. Das Nacoes Unidas,
22.540 (S. Amaro)
Mail Address: Caixa Postal, 8239
01.000-Sao Paulo-SP-Brazil
Phone: 247-1011-5919-1100
Cable Address: CATERPILLAR SP. BRAZIL
Telex No.: 391-01122824 & 391-01121496
Europe, Africa, and Middle East:Caterpillar Overseas S.A./Power Systems
YA50 76, Route de Frontenex
P.O. Box 456
1211 Geneva 6
Switzerland
Cable Address: CATOVERSEA
Telex No.: 413323
Phone: (022) 737 4444
Telecopier: (022) 737 4984
Australia and New Zealand:Caterpillar of Australia Ltd.
1 Sharps Road, Private Mail Bag 4
Tullamarine, Victoria 3043 Australia
Telex: AA30240
Cable: CATERPILLAR MELB
Phone: (03) 3399333
Far East (except Japan and Australia):Caterpillar Asia Pre. Ltd.
150 Beach Road
#11-00 Gateway West
Singapore 0718
Phone: 3900300
Fax: 3900302
Japan:Caterpillar Mitsubishi Ltd.
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229 Japan
Telex No.: 2872-261CM HAJ
Cable Address: CATERBISHICO SAGAMIHARA
Phone: Sagamihara (0427) 62-1121